Work Flow

WORK FLOW (WITH GR8-1200 NI)

Starting System Diagnosis with GR8-1200 NI

To test the starting system, use the following special service tool:

Multitasking battery and electrical diagnostic station GR8-1200 NI

note	Refer to the diagnostic station Instruction Manual for proper starting system diagnosis procedures.

Overall Sequence

Detailed Flow

note	To ensure a complete and thorough diagnosis, the battery, starter motor and alternator test segments must be done as a set from start to finish. If any malfunction is found, immediately disconnect the battery cable from the negative terminal.

1.DIAGNOSIS WITH MULTITASKING BATTERY AND ELECTRICAL DIAGNOSTIC STATION GR8-1200 NI

Perform starting system test with Multitasking battery and electrical diagnostic station GR8-1200 NI. For details and operating instructions, refer to diagnostic station Instruction Manual.

How is the test result?

: Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again. Refer to diagnostic station instruction manual.

: Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again. Refer to diagnostic station instruction manual. If second test result is “REPLACE BATTERY”, then do so. Perform battery test again to confirm repair.

2.COMPARISON BETWEEN ENGINE COOLANT AND CRANKING VOLTAGE

Compare engine coolant temperature and the cranking voltage with the specifications.

Minimum Specification of Cranking Voltage Referencing Coolant Temperature

Engine coolant temperature [°C (°F)]	Voltage [V]
−30 to −20 (−22 to −4)	8.6
−19 to −10 (−2 to 14)	9.1
−9 to 0 (16 to 32)	9.5
More than 1 (More than 34)	9.9

Is the voltage less than the specified value?

3.CHECK ENGINE START

Crank engine and check that engine starts.

Does engine start?

4.CHECK RETURN OF PINION GEAR

Check that pinion gear returns to original position after engine starts.

Does pinion gear return?

Starter motor is OK. INSPECTION END

5.CHECK ENGINE SPEED WITH CRANKING

Check that engine turns while cranking.

Does engine turn by cranking?

6.CHECK STARTER MOTOR TURNING WITH CRANKING

Check that starter motor runs smoothly without abnormal noise at cranking.

Does starter motor turn normally?

Check ignition/fuel system.

Check engine mechanical and power train system.

7.CHECK STARTER MOTOR SPEED WITH CRANKING

Check that starter motor turns while cranking.

Does starter motor turn at cranking?

8.CHECK PINION GEAR AND RING GEAR ENGAGEMENT

Check condition of pinion and ring gear engagement.

Is inspection result normal?

Check engine mechanical and power train system.

Check pinion protrusion length. Refer to Inspection

9.CHECK POWER SUPPLY CIRCUIT

Check the following conditions.

Fuse and fusible link
Charge condition, corrosion and connection condition of battery. Refer to Diagnosis Procedure.

Are these inspection results normal?

Repair as needed.

10.CHECK STARTING SYSTEM WIRING

Check the following.

“B” terminal circuit. Refer to Diagnosis Procedure.
“S” terminal circuit. Refer to Diagnosis Procedure.

Are these inspection results normal?

Repair as needed.

11.CHECK MAGNETIC SWITCH OPERATION

Check magnetic switch operation. Refer to Inspection

Does magnetic switch operate normal?

Replace magnetic switch or starter motor.

12.CHECK PINION TURNING

Remove starter motor.
Check that pinion turns smoothly by hand.

Does pinion turn normally?

Perform no-load test of starter motor. Refer to Inspection

Check pinion clutch. Refer to Inspection

WORK FLOW (WITHOUT GR8-1200 NI)

Overall Sequence

Detailed Flow

note	If any malfunction is found, immediately disconnect the battery cable from the negative terminal.

1.CHECK ENGINE START

Crank engine and check that engine starts.

Does engine start?

2.CHECK RETURN OF PINION GEAR

Check that pinion gear returns to original position after engine starts.

Does pinion gear return?

Starter motor is OK. INSPECTION END

3.CHECK ENGINE SPEED WITH CRANKING

Check that engine turns while cranking.

Does engine turn by cranking?

4.CHECK STARTER MOTOR TURNING WITH CRANKING

Check that starter motor runs smoothly without abnormal noise at cranking.

Does starter motor turn normally?

Check ignition/fuel system.

Check engine mechanical and power train system.

5.CHECK STARTER MOTOR SPEED WITH CRANKING

Check that starter motor turns while cranking.

Does starter motor turn at cranking?

6.CHECK PINION GEAR AND RING GEAR ENGAGEMENT

Check condition of pinion and ring gear engagement.

Is inspection result normal?

Check engine mechanical and power train system.

Check pinion protrusion length. Refer to Inspection

7.CHECK POWER SUPPLY CIRCUIT

Check the following conditions.

Fuse and fusible link
Charge condition, corrosion and connection condition of battery. Refer to Diagnosis Procedure.

Are these inspection results normal?

Repair as needed.

8.CHECK STARTING SYSTEM WIRING

Check the following.

“B” terminal circuit. Refer to Diagnosis Procedure.
“S” terminal circuit. Refer to Diagnosis Procedure.

Are these inspection results normal?

Repair as needed.

9.CHECK MAGNETIC SWITCH OPERATION

Check magnetic switch operation. Refer to Inspection

Does magnetic switch operate normal?

Replace magnetic switch or starter motor.

10.CHECK PINION TURNING

Remove starter motor.
Check that pinion turns smoothly by hand.

Does pinion turn normally?

Perform no-load test of starter motor. Refer to Inspection

Check pinion clutch. Refer to Inspection